Body Armor Protection System

ABSTRACT

The present invention relates to a body armor system designed to maximize protection, optimize mobility and reduce fatigue. More particularly, the system consists of a set of external, highly ergonomic hard armor plates in both ballistic and non-ballistic (riot) configurations, some of which utilize articulating, and/or interleaving segments, in combination with ballistic fabrics and or highly contoured pressed foam padding and harness systems that is flexible and lighter but still provides maximum protection. According to a preferred embodiment, an articulating plate assembly is formed by using plate segments that have at least two (2) step variation in the thickness of each plate along the adjoining seam line between each plate segment so as to facilitate an interleaving, articulating plate system that aids in defeating projectiles that may strike along the seam of adjoining plate segments.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 61/294,387 filed Jan. 12, 2010.

FIELD OF INVENTION

The present invention relates to a body armor system designed to maximize protection, optimize mobility and reduce fatigue. More particularly, the system consists of a set of external, highly ergonomic hard armor plates in both ballistic and non-ballistic (riot) configurations, some of which utilize articulating, and/or interleaving segments, in combination with ballistic fabrics and or highly contoured pressed foam padding and harness systems.

BACKGROUND OF INVENTION

There are numerous body armor systems available on the market today. However, such systems tend to be heavy and bulky.

U.S. Pat. No. 5,771,489 discloses a flexible body armor that is relatively lightweight and capable of biaxial flexure is disclosed. The flexible body armor employs a novel penetration-resistant hinge for joining adjacent armor plates along one axis and uses sliding overlaps between the same adjacent armor plates along the perpendicular axis in order to achieve biaxial flexibility. Also disclosed are several embodiments of the penetration-resistant hinge and the sliding overlap. In a preferred body armor in accordance with the invention, the penetration-resistant hinges and sliding overlaps are part of a frame which provides edge confinement to ceramic armor plates used in the body armor.

U.S. Pat. No. 3,867,239 discloses a flexible armor material comprising an array of platelets with contoured edges or reinforced joints supported by a flexible membrane.

U.S. Pat. No. 5,996,115 discloses an articulated body armor garment having a single layer of ceramic tiles adhesively attached to a flexible fragment-trapping blanket. A foam spacer layer behind the blanket at least partially contains deformation of the blanket in a ballistic attack. The blanket preferably includes at least forty plies of a ballistic cloth stitched together in a quilt pattern. Edge areas of the ceramic tiles are beveled so that edges of adjacent tiles overlap, thus enabling the array of tiles to present an essentially continuous unbroken surface to a projectile.

U.S. Pat. No. 4,483,020 discloses a vest having projectile-stopping capabilities, including a network of inner shock-resistant plates lying under a layer of ballistic material to minimize the force imparted by a slowing projectile upon a wearer of the vest.

US Patent Publication 2009/223589 discloses a bulletproof vest that is adapted to the body and which comprises a part which can be adapted to the front side of the body and a back part which can be adapted to the back side of the body and both parts comprise several pieces of protective sheets with the help of which the areas of the body which are to be protected, are covered. Said adjacent pieces of protective sheets are joined next to each other with a butt connection so that a butt connection hinge is at a diagonal angle preferably at an angle of 30-60 degree and an overlapping, protective skirting belongs to the outer side of the butt connection hinge and is thinner than the actual protective sheets.

U.S. Pat. No. 4,241,457 discloses a bullet-proof or similar protective garment incorporating segmented panels. The panels are employed to resist penetration of a bullet or other projectile. The panels are configured such that they are flexible or hinged under ordinary conditions, but rigid upon projectile impact. The hinging is achieved by the disposition of the segments of the panel in relationship to the adjacent segments

U.S. Pat. No. 4,413,357 discloses a protective shield such as a personal, bullet-proof garment, formed by a separable front panel and back panel, fastened together into a vest by detachable tabs, that is conformable to torso movement with comfort. The outer, penetration-resisting, layer of the shield comprises at least eight and preferably twenty-eight, individual superposed plies of close woven fabric of aramid fibers, the intermediate, impact-spreading layer of the shield, comprises at least one ply of thin, flexible, impervious plastic sheeting such as polycarbonate and the inner, impact-cushioning, layer of the shield is formed of soft, relatively thick, foam plastic, to absorb impact and bullet bulge of the polycarbonate sheeting.

Accordingly, there is a need for a flexible and lighter body armor that still provides maximum protection.

SUMMARY OF INVENTION

It is an object of the present invention to provide a body armor system that maximizes protection, optimizes mobility and reduces fatigue.

It is another object of the invention to provide a body armor system that comprises of a set of external, highly ergonomic hard armor plates (in both ballistic and non ballistic configurations) that utilizes articulating and/or interleaving segments in combination with ballistic fabrics and/or highly contoured pressed foam padding and harness systems.

It is another object of the present invention to provide a system of highly ergonomic hard armor ballistic plates, preferably twelve (12), designed to match the contours of the human body, which utilizes soft armor ballistic border panels and are held in place with a unique pressed urethane foam pad harness system that is designed to match the contours of each plate and provide a strong, lightweight, buoyant support system that aids in the reduction of the overall system weight.

It is another object of the present invention to provide a system wherein the knee cap is protected through the use of specific contours that remove all weight and pressure from the knee when kneeling, and places the force of the wearer's body against the upper portion of the shin, thus alleviating any potential wear stress on the knee.

It is a further object of the present invention to provide hard armor plates comprising numerous layers of polymer armors pressed under heat and pressure to form cohesive plates, preferably utilizing an external layer of ceramic designed to defeat armor piercing rounds.

It is a further object of the present invention to provide soft armor panels comprising numerous layers of Kevlar® brand fabric¹, Twaron® brand fabric² or a similar material as would be well know to one of skill in the art, and are held together by stitching, external bags and/or pockets. ¹Kevlar is the registered trademark for a light, strong para-aramid synthetic fiber developed by DuPont in 1965.²Twaron is the brand name of Teijin Aramid for a para-aramid. It is a heat-resistant and strong synthetic fiber developed in the early 1970s by AKZO, division Enka, later Akzo Industrial Fibers. The research name was originally Fiber X, but it was soon called Arenka before it was introduced as a commercial product under the name Twaron.

It is a further object of the invention to provide a body armor system that can easily integrate additional components to improve wearability, functionality or some other aspect of the armor such as wires for communication, tubing for cooling systems or substances for chemical and/or radiological protection.

The present invention is designed and manufactured in such a way as to maximize protection while at the same time reducing weight and providing unprecedented mobility as compared to current military systems such as the Improved Outer Tactical Vest (IOTV) as developed for the Army and the Modular Tactical Vest (MTV) as developed for the Marine Corps. The present invention allows for an increased hard armor plate coverage area without an increase in overall weight by reducing soft armor panel size compared to prior systems. The design of the present invention in combination with a lightweight pressed foam pad and harness system results in a reduction of over 4 lbs as compared to comparable systems while providing increased hard plate coverage and a better weight distribution as a result of highly contoured geometry.

There has thus been outlined, rather broadly, the more important features of the present invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described further hereinafter.

In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may be readily utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that equivalent constructions insofar as they do not depart from the spirit and scope of the present invention, are included in the present invention. For a better understanding of the invention, its operating advantages and the aims attained by its uses, references should be had to the accompanying drawings and descriptive matter which illustrate preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the ballistic torso of the present invention.

FIG. 2 a is a front view of the ballistic chest plate of the present invention.

FIG. 2 b is a side view of the ballistic chest plate of the present invention.

FIG. 2 c is a top view of the ballistic chest plate of the present invention.

FIG. 3 a is a front view of the ballistic back plate of the present invention.

FIG. 3 b is a side view of the ballistic back plate of the present invention.

FIG. 3 c is a top view of the ballistic back plate of the present invention.

FIG. 4 a is a front view of the ballistic side plate of the present invention.

FIG. 4 b is a side view of the ballistic side plate of the present invention.

FIG. 4 c is a top view of the ballistic side plate of the present invention.

FIG. 5 a is a front view of the non-ballistic chest plate of the present invention.

FIG. 5 b is a side view of the non-ballistic chest plate of the present invention.

FIG. 5 c is a top view of the non-ballistic chest plate of the present invention.

FIG. 6 a is a front view of the non-ballistic back plate of the present invention.

FIG. 6 b is a side view of the non-ballistic back plate of the present invention.

FIG. 6 c is a top view of the non-ballistic back plate of the present invention.

FIG. 7 is a front view of the non-ballistic chest plate pad of the present invention.

FIG. 8 is a front view of the non-ballistic back plate pad of the present invention.

FIG. 9 is a perspective view of the harness of the ballistic torso of the present invention.

FIG. 10 is an exploded perspective view of the harness of the ballistic torso of the present invention.

FIG. 11 is a front view of the chest pocket of the harness of the ballistic torso of the present invention.

FIG. 12 is a rear view of the chest pocket with a soft armor lining, of the harness of the ballistic torso of the present invention.

FIG. 13 is a rear view of the chest pocket without a soft armor lining of the harness of the ballistic torso of the present invention.

FIG. 14 is a front view of the back pocket of the harness of the ballistic torso of the present invention.

FIG. 15 is a rear view of the back pocket with a soft armor lining, of the harness of the ballistic torso of the present invention.

FIG. 16 is a rear view of the back pocket without a soft armor lining of the harness of the ballistic torso of the present invention.

FIG. 17 is a front view of the side pocket of the harness of the ballistic torso of the present invention.

FIG. 18 is a rear view of the side pocket with a soft armor lining, of the harness of the ballistic torso of the present invention.

FIG. 19 is a rear view of the side pocket without a soft armor lining of the harness of the ballistic torso of the present invention.

FIG. 20 is a front view of the ballistic upper arm protection system of the present invention with 0.5″ plates.

FIG. 21 is a rear view of the ballistic upper arm protection system of the present invention with 0.5″ plates.

FIG. 22 is a side view of the ballistic upper arm protection system of the present invention with 0.5″ plates.

FIG. 23 is a front view of the ballistic upper arm protection system of the present invention with 0.25″ plates.

FIG. 24 is a rear view of the ballistic upper arm protection system of the present invention with 0.25″ plates.

FIG. 25 is a front view of the upper arm padding system of the present invention.

FIG. 26 is a front view of the deltoid protection system of the present invention.

FIG. 27 is a rear view of the deltoid protection system of the present invention.

FIG. 28 is a side view of the deltoid protection system of the present invention.

FIG. 29 is a front view of the deltoid pad of the present invention.

FIG. 30 is a front view of the non-ballistic upper extremity protection system of the present invention.

FIG. 31 a is a front view of the non-ballistic shoulder plate of the present invention.

FIG. 31 b is a rear view of the non-ballistic shoulder plate of the present invention.

FIG. 31 c is a front view of the non-ballistic bicep plate of the present invention.

FIG. 31 d is a rear view of the non-ballistic bicep plate of the present invention.

FIG. 32 a is a front view of the non-ballistic stepped shoulder plate of the present invention.

FIG. 32 b is a rear view of the non-ballistic stepped shoulder plate of the present invention.

FIG. 32 c is a front view of the non-ballistic stepped bicep plate of the present invention.

FIG. 32 d is a rear view of the non-ballistic stepped bicep plate of the present invention.

FIG. 33 a is a front view of the partial gauntlet of the present invention.

FIG. 33 b is a rear view of the partial gauntlet of the present invention.

FIG. 34 is a front view of the forearm pad of the present invention.

FIG. 35 is a perspective view of the full gauntlet of the present invention.

FIG. 36 is a side view of the thigh plate of the present invention.

FIG. 37 is a front view of the thigh plate of the present invention.

FIG. 38 is a front view of the thigh pad of the present invention.

FIG. 39 is a front view of the ballistic shin guard of the present invention with 0.5″ plates.

FIG. 40 is a rear view of ballistic shin guard of the present invention with 0.5″ plates.

FIG. 41 is a side view of ballistic shin guard of the present invention with 0.5″ plates.

FIG. 42 is a rear view of ballistic shin guard of the present invention with 0.25″ plates.

FIG. 43 is a side view of ballistic shin guard of the present invention with 0.25″ plates.

FIG. 44 is a rear view of non-ballistic shin guard of the present invention with 0.25″ plates.

FIG. 45 is a side view of non-ballistic shin guard of the present invention with 0.25″ plates.

FIG. 46 is a front view of the shin pad of the present invention.

FIG. 47 is a perspective view of a preferred embodiment.

FIG. 48 is a front view of a preferred embodiment.

FIG. 49 is a front view of a preferred embodiment.

FIG. 50 a is front view of a square loop ring buckle.

FIG. 50 b is a perspective view of quick release buckles.

FIG. 50 c is a schematic of a ratcheting ladders strap buckle.

FIG. 50 d is a schematic of a ladder strap.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The body armor of the present invention provides ballistic and/or non-ballistic coverage to the wearer without hindering movement by utilizing complex hard armor plate and harness contours specifically designed to mimic the geometry of the human body. This ergonomic design allows for the weight of the system to be more evenly distributed over a large portion of the wearers body, thus eliminating some of the stress associated with long term use of ballistic plate systems. In addition, the present invention provides a greater level of overall comfort and mobility, which results in extended operational efficiency.

According to the present invention, the standard hard armor plate thickness used in the torso plates ranges from roughly from about 0.125″ to about 1.25″, preferably from about 0.25″ to about F. According to the present invention, the soft armor panels range in thickness from about 0.25″ to about 1.5″, preferably about 0.375″ (equivalent to 30 plies of Kevlar® fabric,) depending on the particular application. The thickness of the ceramic breaker plate that is used in conjunction with the polymer armor to achieve National Institute of Justice (NIJ) Level IV protection is roughly about 0.2″ to about 0.5″, depending on the specific applications.

FIG. 1 is a perspective view of the ballistic torso (10) of the body armor protection system of the present invention. The ballistic torso (10) comprises a ballistic chest plate (12), a ballistic back plate (14) and ballistic side plates (16). FIGS. 2, 3 and 4 show the contours of the ballistic chest plate (12), back plate (14) and side plates (16). Specifically, FIG. 2 a is a front view of the ballistic chest plate (12), FIG. 2 b is a side view of the ballistic chest plate (12) and FIG. 2 c is a top view of the ballistic chest plate (12) of the body armor protection system of the present invention. FIG. 3 a is a front view of the ballistic back plate (14), FIG. 3 b is a side view of the ballistic back plate (14) and FIG. 3 c is a top view of the ballistic back plate (14) of the body armor protection system of the present invention. FIG. 4 a is a front view of the ballistic side plate (16), FIG. 4 b is a side view of the ballistic side plate (16) and FIG. 4 c is a top view of the ballistic side plate (16) of the body armor protection system of the present invention.

The ballistic torso (10) protection system ranges in thickness from about 0.5″ to about 1″ thick, with the preferred embodiment comprising about fifty plies of pressed polymer based armor material combined with an about 0.4″ thick ceramic based breaker plate attached to the exterior surface in order to provide NIJ Level IV protection. The ballistic system is preferably designed to fit into a vest or harness system using pocket systems as further described herein in order to maintain the position of each plate relative to the wearers body.

The non-ballistic torso protection system comprises a non-ballistic chest plate (20), a non-ballistic back plate (22), a non-ballistic chest plate pad (24) and a non-ballistic back plate pad (26). FIGS. 5, 6, 7 and 8 show the contours of the non-ballistic chest plate (20), non-ballistic back plate (22), non-ballistic chest plate pad (24) and non-ballistic back plate pad (26) respectively. More specifically, FIG. 5 a is a front view of the non-ballistic chest plate (20), FIG. 5 b is a side view of the non-ballistic chest plate (20) and FIG. 5 c is a top view of the non-ballistic chest plate (20) of the non-ballistic body armor protection system of the present invention. FIG. 6 a is a front view of the non-ballistic back plate (22), FIG. 6 b is a side view of the non-ballistic back plate (22) and FIG. 6 c is a top view of the non-ballistic back plate (22) of the non-ballistic body armor protection system of the present invention.

The plates of the non-ballistic torso protection system ranges in thickness from about 0.125″ to 0.375″, preferably about 0.25″ and are designed to provide protection against blunt force impact trauma such as that typically associated with riot and correctional conflicts.

The non-ballistic chest plate pad (24) and non-ballistic back plate pad (26) preferably comprises pressed foam. According to a further preferred embodiment, the non-ballistic chest plate pad (24) and non-ballistic back plate pad (26) comprise extension tabs (28), more preferably four (4) extension tabs (28), two (2) at the top and (2) on the side as shown in FIGS. 7 and 8.

The non-ballistic system of the present invention preferably uses an adhesive hook (not shown) on the inner surface of the plates (20, 22) that corresponds to a loop exterior (not shown) connected to the extension tabs (28) which protrude from the top and sides in order to serve as an attachment point for harness straps, thus eliminating the need for an additional garment or carrier system. According to a preferred embodiment, each extension tab (28) preferably runs through a square loop ring buckle on the opposing side and folds back on themselves, held in place through a hook and loop fixture mechanism. Other mechanisms of attaching the pads to the plates such as snaps, clips, quick release buckles, etc., may also be used as would be known to one of ordinary skill in the art.

It should also be noted that while the contoured harness system described herein is the preferred embodiment for ballistic system, the ballistic plates can also be held in position by using the same internal pad system described for use in the non-ballistic systems described herein.

The ballistic torso protection system (10) is preferably held in place with a harness system (30), as shown in FIG. 9, comprised of a series of plate pockets, molded using press formed urethane foam sheets. The harness system (30) preferably comprises four (4) pockets, a chest pocket (32), a back pocket (34) and two (2) side pockets (36), one on each side. Each of the four (4) pockets are contoured to match the specific geometry of each corresponding ballistic plate (12, 14 16), and consist of two parts: an external pocket (31) which forms a cavity and surrounds the ballistic plate (12, 14, 16) along the outer face and lateral edges, and an internal face (33) that covers the inner most portion of each plate (12, 14, 16) thus forming the complete pocket (32, 34, 36) as shown in FIG. 10.

The external pocket (31) is formed into a cavity which covers each plate (12, 14, 16) on the front and sides and forms the primary base of support for each plate (12, 14, 16) as shown in FIGS. 11, 14 and 17, respectively. The internal face (33) can be preferably formed with either a flat sheet of pressed foam or an extruded component which provides padding in specific sections along the contact points of the wearer's body and optionally. More preferably, additional padding can be added on the exterior to provide protection to the ceramic component of each ballistic plate. The external pocket (31) and internal face (33) are then preferably stitched together along the outer perimeter flange (35) of the lower edge and about half way up the sides, in order to form a secure seat for each ballistic plate (12, 14, 16) to rest. Velcro®³ (or a similar material as would be known to one of skill in the art) is then used to seal the remaining adjoining perimeter flange segments allowing for ease of use while maintaining a secure enclosure.

A 2″ border of soft armor (38) as shown in FIGS. 12, 15 and 18 for the chest pocket (32), back pocket (34) and side pocket (36) respectively, can preferably be used to eliminate the need for a standard soft armor vest under the ballistic torso (10) of the body armor of the present invention. Using stand alone Level IV ballistic plates (12, 14, 16) as the core of the system, a Level IIIA soft armor (38) about 0.375″ thick can preferably be placed behind each pocket (32, 24, 26) and cut to the specific geometry of each corresponding plate (12, 14, 16) and extending about 1″ towards the interior of each ballistic plate (12, 14, 16) and about 1″ away from the interior of each ballistic plate (12, 14, 16) to provide extended protection in the gaps between the ballistic plates (12, 14, 16) while significantly reducing the overall weight of the system as compared to standard plate carrier systems. The soft armor (38) is preferably comprised of about thirty (30) plies of Kevlar® or similar fabric, cut to size, and encased in a fabric outer shell, then held in place using a hook and loop fixture or equivalent as would be known by one of skill in the art. ³Velcro is a brand name of fabric hook-and-loop fasteners.

Alternatively, the internal face (33) of the chest pocket (32), back pocket (34) and side pocket (36) of the harness system (30) are not lined with soft armor (38) as shown in FIGS. 13, 16 and 19 respectively.

In the preferred embodiment, a series of adjustable straps, preferably six (6) (three (3) on each side), (not shown) extend from the upper strap attachment tabs (37 a) and the lateral strap attachment tabs (37 b) of the chest pocket (32) as shown in FIG. 11 and the back pocket (34) as shown in FIG. 14 of the harness system (30) and run over the shoulders and around the waist, through strap support loops (39) stitched on the back of each side pocket (36) as shown in FIG. 19 of the harness system (30), binding the harness system (30) together using a combination of Velcro®, square loop ring buckles, quick release buckles and/or other suitable mechanisms, to maintain the position of each ballistic plate (12, 14, 16) relative to the corresponding parts of the wearer's body.

The body armor of the present invention preferably comprises a ballistic upper arm protection system (40) that comprises two separate armor segments: a shoulder plate (thick 42 a or thin 42 b) and a bicep plate (thick 44 a or thin 44 b) that are designed to correspond to the contours of the human upper arm as seen in FIGS. 20-24. Each plate (42 a and 44 a, or 42 b and 44 b) interacts with a system of pads and support straps in order to maintain their position relative to the upper arm and each adjoining plate, and to facilitate a full range of unhindered movement.

The ballistic upper arm protection system (40) is held in place by using a pressure formed upper arm padding system (41) that rests on the interior of each hard armor plate (42 a and 44 a, 42 b and 44 b) and is held in position through the use of a hook and loop Velcro® system or other equivalent system as would be well known to one of skill in the art. The interior of each hard armor plate (42 a and 44 a, 42 b and 44 b) is lined with an adhesive hook system (not shown) placed in specific positions relative to the position of each loop system (not shown) of the padding system (41). As seen in FIG. 25, a vertical strap attachment point (46 a) is positioned at the top of the shoulder pad (43) and horizontal strap attachment points (46 b) of each upper arm padding system (41) to provide a point of attachment for webbing (not shown) that will allow for the addition of a fully adjustable strap system (not shown). Various darts (48) in the pattern of each upper arm padding system (41) allows the padding to take the contoured shape of the interior of each plate (42 a and 44 a, 42 b and 44 b).

A primary support strap (not shown) runs from the lateral portion of the torso harness system (30) (or any modified vest or harness), and connects via a square loop ring buckle or other mechanism, with the vertical strap attachment point (46 a) that extends from the top of the upper arm padding system (41) at the upper most inward radius of the deltoid plate (52) and then extends downward over the gap between the upper shoulder plate (42 a or 42 b) segment and the lower bicep plate (44 a or 44 b) plate segments thereby maintaining the position of each plate relative to its corresponding segment.

The bicep pad (45) has two horizontal strap attachment points (46 b) that extend horizontally from the bicep pad (45) and form the primary attachment point for straps (not shown) that run across the inside of the wearer's arm and around the outside of the bicep plate (44 a or 44 b). The forward horizontal strap attachment point (46 b) preferably contains webbing (not shown) stitched to the tab on one end and around a square loop ring on the other. The opposing side contains a strap stitched to the tab (not shown) that loops through the square loop ring and folds back over itself and around the outside of the bicep plate (44 a or 44 b). The strap then maintains its position with a hook and loop attachment feature or other equivalent means.

The shoulder plate (42 a or 42 b) interleaves with the other arm plates in concert with the wearer's movements allowing the plates to overlap in order to provide unhindered flexibility of the shoulder and elbow joints of the wearer.

The design of the present invention allows for maximum protection to the upper arm and shoulder while maintaining an unhindered range of motion. Large size, Level IIIA+ systems weigh about 1.8 lbs, preferably about 1.6 lbs per side and are about 0.125″ to about 0.75″ thick, preferably about 0.25″ to about 0.65″ thick, thus providing a viable solution for protection from improvised explosive devices (IEDs), riot situations, correctional hazards and general mounted and dismounted infantry operations. FIGS. 20, 21 and 22 illustrate a preferred embodiment with a 0.5″ (42 a and 44 a) ballistic upper arm protection system (40) and FIGS. 23 and 24 illustrate a further preferred embodiment with a 0.25″ (42 b and 44 b) ballistic upper arm protection system (40).

According to another preferred embodiment, the body armor of the present invention comprises a deltoid protection system (50) comprising a deltoid plate (52) as shown in FIGS. 26, 27 and 28, and a deltoid pad (54) as shown in FIG. 29. This modification of the ballistic upper arm protection system (40) is designed to provide a simplified solution with less coverage area and reduced weight (about 1 lb per side in Level IIIA configurations) as compared to the complete ballistic upper arm protection system (40).

The deltoid protection system (50) of the present invention is specifically designed as an alternative to the existing military specification Deltoid Auxiliary Protection System (DAPS). By using hard armor instead of existing soft armor solutions, the deltoid protection system (50) is capable of resisting small arms fire and blunt force impact trauma with greater efficiency thereby reducing the effects of projectiles, fragmentation, blunt force impact trauma and explosive compression. Due to the ability of hard armors to be formed into complex curves and contours, less material is needed to cover the same area due to the efficiencies of ergonomic design, which allows for the development of systems that are lighter than existing soft armor systems but far more effective.

The deltoid protection system (50) is held in place through the use of a pressure formed deltoid pad (54) that rests on the interior of each hard armor deltoid plate (52) and is held in position through the use of a hook and loop Velcro® system or equivalent mechanism. The interior of each hard armor deltoid plate (52) is preferably lined with an adhesive hook system (not shown) placed in specific positions relative to the position of each loop backed deltoid pad (54) segment. Extensions at either end of each deltoid pad (54) provide a point of attachment for webbing that allows for the addition of a fully adjustable strap.

Preferably, a vertical strap attachment point (46 a) extends from the upper most portion of the deltoid pad (54) and provides the primary mode of support whereby a primary strap (not shown) extends from the deltoid pad (54) and runs through a square loop ring buckle (not shown) and is capable of being added to any standard soft armor vest, harness or carrier system, looping over itself and laying flat against the interior of the deltoid pad (54) and is held in place through the use of a hook and loop attachment feature. Of course, other equivalent methods of attachment are also contemplated as would be known by one of skill in the art.

More preferably, horizontal strap attachment points (46 b) allow for straps (not shown) to be run across the inside of the arm in order to maintain the position of the deltoid plate (52) relative to the wearer's arm. The strap on the leading edge of the horizontal strap attachment point (46 b) contains a square loop ring buckle on the end (not shown), and the opposite side contains a strap (not shown) which is stitched in place and runs through the square loop ring on the other side. The strap then folds over itself, cinches tight around the inside of the arm and is held in place through the use of a hook and loop attachment feature. Other equivalent methods of attachment are also contemplated as would be known by one of skill in the art.

Alternatively, a lower strap attachment point (46 c) is used as an adjustable strap and fits into a feed-through buckle sewn into any standard battle dress uniform (BDU). This provides two (2) alternatives for maintaining the position of the deltoid plate (52) relative to the wearer's arm, based on preference.

According to another preferred embodiment, an upper extremity protection system provides either ballistic or non-ballistic protection. The ballistic upper extremity protection system is made as the ballistic upper arm protection system described above. The non-ballistic upper extremity protection system (60) as shown in FIG. 30 comprises high-density polyethylene (HDPE) or similar material and is designed to provide protection to the wearer against blunt force impact trauma during intense hand to hand confrontations and/or similar scenarios or risk environments.

As seen in FIG. 30, the non-ballistic upper extremity protection system (60) comprises an articulating upper arm segment (62) which is comprised of two adjoining segments, a shoulder plate (42 c) and a bicep plate (44 c) which move in conjunction with the wearers' body, and a stationary partial gauntlet (64) which is comprised of a single, highly contoured hard plate. This configuration allows the non-ballistic upper extremity protection system (60) to be scalable to meet the needs of specific missions and scenarios.

The articulating upper arm segments (62) are held in position through the use of the same pad support system used in the ballistic upper arm protection system (40), with an upper, vertical support strap and two lateral, horizontal extensions which protrude from the primary pad and are affixed to adjustable straps which connect to customizable attachments points and run through square loop ring buckles and Velcro® tight along the adjoining segments (not shown). The pad is held in place through the use of the same adhesive hook material, placed on the inside of each hard armor plate in specific locations relative to the placement of each loop backed pad segment (not shown).

The partial gauntlet (64) is held in position through the use of adjustable straps which extend laterally from four (4) tabs which protrude laterally from a custom pressed foam pad that is affixed to the interior of the gauntlet plate through the use of an adhesive hook material which is affixed to the interior of each hard armor plate segment corresponding to the location of each loop backed pad segment (not shown). A square loop ring buckle on one side meets with a strap which extends from the tab on the other side. The strap is looped through the square loop ring buckle and wrapped around the exterior of the gauntlet using a hook and loop, Velcro®, attachment feature (not shown). Of course, other means of attachment would be well know to one of ordinary skill in the art.

According to a preferred embodiment, there is a 45-75 degree angular separation between the should plate (42 c) and the bicep plate (44 c) segments is utilized in order to allow for smooth articulation between adjoining plate segments as seen in FIGS. 31 a, b, c and d. However, according to another preferred embodiment, the segments articulate by virtue of a stepped shoulder plate (42 d) and a stepped bicep plate (44 d) as seen in FIGS. 32 a, b, c and d, wherein each plate contains an angled segment, with adjoining angles between 45-75 degrees. As seen in FIGS. 32 a, b, c and d, the use of a two-step variation in the thickness of each plate forms an interleaving seam (63) along the articulation point between adjoining stepped should plate (42 d) and stepped bicep plate (44 d) segments. According to a further preferred embodiment, the segments can include three (3) or more steps, and can be applied to other armor segments, in various positions and combinations, in order to facilitate additional articulation points.

The partial gauntlet (64) as shown in FIGS. 33 a and b and the full gauntlet (65) as shown in FIG. 35, are highly contoured armor plates that can be formed in both ballistic and non-ballistic configurations, designed to function in both defensive and offensive situations. Defensively the gauntlets (64 or 65) provide hard armor protection to the wearers' forearms allowing for a greater level of physical protection from a wide variety of threats. Offensively the gauntlets (64 or 65) provide for blocking and striking capabilities currently available only through the use of additional equipment such as batons and shields.

FIGS. 33 a and b show the partial gauntlet (64), which is the same design for both ballistic and non-ballistic applications. The partial gauntlet (64) covers the top portion of the forearm without forming a complete shell around the forearm. According to another preferred embodiment seen in FIG. 35, the full gauntlet (65) uses the same contours as the partial gauntlet (64), expanded to form a complete shell around the forearm, with a removable section that allows the wearer to easily put on and take off the full gauntlet (65). The full gauntlet (65) is preferably made of three (3) separate plates, a top plate (65 a), an outside plate (65 b) and an inside plate (65 c) as seen in FIG. 35. Preferably, two of the plates, the top plate (65 a) and the outside plate (65 b) of the full gauntlet (65) are fused together via ultrasonic welding or other suitable means in order to form a solid base for the third plate segment, the inside plate (65 c).

The partial gauntlet (64) is held in place through the use of a pressure formed gauntlet pad (66) that rests on the interior of each hard armor partial gauntlet (64) plate and is held in position through the use of a hook and loop Velcro® system or other suitable mechanism. The interior of each hard armor partial gauntlet (64) plate is lined with an adhesive hook system placed in specific positions relative to the position of each loop backed pad segment (not shown). The gauntlet pad (66) is then mechanically attached to each partial gauntlet (64) plate, and a strap with a hook and loop closure system in the appropriate sections is affixed to horizontal strap attachment points (46 b), of which there are preferably four (4) that protrude from each gauntlet pad (66) segment as seen in FIG. 34.

On one side the horizontal strap attachment points (46 b) contain a square loop ring buckle, and on the other side the horizontal strap attachment points (46 b) contain a long strap with hook and loop in appropriate section (not shown). The long strap runs through the square loop ring buckle and loops back over itself. The strap then runs around the outside of the partial gauntlet (64) plate and is held in position through the use of a hook and loop feature or other suitable mechanism.

The full gauntlet (65) preferably uses a series of adhesive backed circular or hexagonal pressed foam pad segments that adhere directly to the interior of the top plate (65 a), the outside plate (65 b) and the inside plate (65 c) in such a manner as to increase airflow within the full gauntlet (65), thus allowing the body to better cool itself by allowing greater heat loss through ventilation (not shown). Preferably, the gauntlet pad (66) can be made of materials that wick away moisture, more preferably with antimicrobial additives that prevent the growth of bacteria. The full gauntlet (65) is preferably held in position over the arm through the use of an exterior plastic strap that consists of a quick release buckle and “ladder strap” closure (not shown) or similar systems to form a strong, tight seal in order to maintain the full gauntlet (65) in position relative to the wearers body.

According to a preferred embodiment, the non-ballistic system also includes a non-ballistic thigh protection system comprising a non-ballistic thigh plate (70) as seen in FIGS. 36 and 37 and a thigh pad (72) as seen in FIG. 38. The thigh protection system is affixed by means to a vertical strap attachment (46 a) and preferably four (4) horizontal strap attachment points (46 b) as described above.

According to another preferred embodiment, the system of the present invention further comprises a shin guard protection system (80) as shown in FIG. 39-45. The shin guard protection system (80) is designed in such a way as to provide frontal ballistic and non ballistic protection to the lower leg, while utilizing a geometric configuration that provides protection to the knee from normal operating stress. The unique geometry of the shin guard protection system (80) enables a seamless fit over the human leg which in turn reduces wear stress and enhances the overall functionality of the system.

The knee cap is protected through the use of specific contours that remove all weight and pressure from the knee when kneeling, and places the force of the wearer's body against the upper portion of the shin, thus alleviating any potential wear stress on the knee. In addition, the formation of a single plate, without segmented sections provides seamless ballistic and non-ballistic protection to the vital areas of the lower leg.

The plates of the shin guard protection system (80) may be thick ballistic shin guards (82 a) as seen in FIGS. 39-41, thin ballistic shin guards (82 b) as seen in FIGS. 42-43, or non-ballistic shin guards (82 c) as seen in FIGS. 44-45.

The shin guard protection system further comprises a shin pad (84) with preferably four (4) horizontal strap attachment points (46 b) as seen in FIG. 46. The shin guard protection system (80) is held in place through the use of the pressure formed shin pad (84) that rests on the interior of each hard armor shin guard (82 a, b or c) plate and is held in position through the use of a hook and loop Velcro® system or other similar mechanism. The interior of each hard armor shin guard (82 a, b or c) plate is lined with an adhesive hook system placed in specific positions relative to the position of each loop shin pad (84). The shin pad (84) is then mechanically attached to each shin guard (82 a, b or c) plate, and a strap with hook and loop in the appropriate places is them affixed to the four (4) horizontal strap attachment points (46 b) that protrude from each (both left and right) shin pad (84).

According to a preferred embodiment, on one side the horizontal strap attachment points (46 b) contain a square loop ring buckle, and on the other side the horizontal strap attachment points (46 b) contain a long strap with hook and loop in appropriate section (not shown). The long straps run through the square loop ring buckles and loop back over themselves (not shown). The strap then runs around the outside of the plate and is held in position through the use of a hook and loop feature (not shown) or other similar mechanism.

According to the present invention, several designs for the shin guard protection system (80) are available depending on the intended use. In a preferred embodiment, the shin guard protection system (80) is a Level IIIA system containing about 30-50 plies of ballistic material and are about 0.375″ to about 0.5″ thick as seen in FIGS. 39-41 showing a further preferred embodiment with thick ballistic shin guards (82 a) that are 0.5″ thick. Various thicknesses may be used to achieve greater or lesser protection, such as shown in FIGS. 42-43 showing thin ballistic shin guards (82 b) that are 0.25″ thick. Alternatively, non-ballistic material may be used to protect against blunt force impact trauma such may be expected in riot situations as seen in FIGS. 44-45 showing non-ballistic shin guards (82 c) that are 0.25″ thick. Large size, Level IIIA+ shin guard protection systems (80) weigh roughly 1.36 lbs per side and provide complete protection against specific ballistic threats including protection against explosive ordinances and blunt force impact trauma.

FIG. 47 shows a preferred embodiment comprising a harness system (30) with a ballistic torso (10) (not shown) and ballistic upper arm protection system (40). FIG. 48 shows a further preferred embodiment for a ballistic assembly, comprising a harness system (30) with a ballistic torso (10) (not shown), ballistic upper arm protection system (40) and either thick ballistic shin guards (82 a) or thin ballistic shin guards (82 b). FIG. 49 is a further preferred embodiment for a non-ballistic assembly comprising a non-ballistic chest plate (20), non-ballistic chest plate pad (24) (not shown), non-ballistic back plate (22), non-ballistic back plate pad (26) (not shown), a non-ballistic upper extremity protection system (60) with a partial gauntlet (64), thigh plates (70), thigh pads (72), and non-ballistic shin guards (82 c).

FIG. 50 shown various attachment means such as a square loop ring buckle (FIG. 50 a), a quick release buckle (FIG. 50 b), a ratcheting ladders strap buckle (FIG. 50 c) and a ladder strap (FIG. 50 d).

A weight analysis of the various components of the body armor protection system depending on the protection level are shown in Table 1 below as compared to known small arms protective inserts (SAPI), DAPS and IOTV.

TABLE 1 Stand Alone Level IV Chest plate 6.6 lbs SAPI 5.4 lbs Volume 108 cubic inches Volume 90 cubic inches Back plate 7 lbs SAPI 5.4 lbs Volume 115 cubic inches Volume 90 cubic inches Side plates 2.2 lbs each SAPI 2.2 lbs each Volume 36.5 cubic inches Volume 36 cubic inches Level IIIA+ Upper arm system 1.6 lbs each DAPS 1.2 lbs each Volume 48 cubic inches Volume 300 square inches (Kevlar ® ) Deltoid plates 1 lb each Volume 30 cubic inches Shin guards 1.36 each Volume 41 cubic inches Harness 4 lbs IOTV 9.3 lbs Volume 120 square inches Volume 1300 square inches (Kevlar ® ) (Kevlar ® )

Materials and Methods of Making

According to the present invention, a polymer based ballistic material such as Spectra Shield®⁴, Dyneema®⁵ HB25, HB50 or HB80 are used alone and/or in combination with Level IV breaker plate materials such as titanium and/or ceramic compounds, which provide resistance to armor piercing rounds, in order to form each hard armor plate. The polymer-based materials allow multiple layers, between 1 and 300, to be placed in a compression mold at about 1500 to 3000 psi at a temperature between about 240-300° F. for a time between about 10 and 120 minutes in order to form a cohesive plate capable of withstanding NIJ Level III+ projectiles in a standalone plate system. When combined with titanium and/or ceramics, these materials are capable of providing NIJ Level IV protection, and can defeat steel core armor piercing rounds up to 7.62 caliber or greater. ⁴Spectra Shield® is a thin, flexible ballistic composite made from layers of unidirectional fibers held in place by flexible resins manufactured by Honeywell. These fibers are arranged so they cross each other at 0 and 90 degree angles, then, both fiber and resin layers are sealed between two thin sheets of polyethylene film similar to saran wrap.⁵Dyneema® is a super strong polyethylene fiber that offers maximum strength combined with minimum weight manufactured by DSM Dyneema. It is up to 15 times stronger than quality steel and up to 40% stronger than aramid fibers, both on weight for weight basis. Dyneema® floats on water and is extremely durable and resistant to moisture, UV light and chemicals.

A monochromatic polymer coating can preferably be applied to the exterior of each plate using HDPE sheets or specially formulated infrared (IR) signature reducing polymers in order to reduce the likelihood of detection by IR devices and to strengthen each hard armor plate in terms of abrasion resistance and overall durability. The polymer coatings can be shaped using a vacuum forming process, and corresponding pieces of material can then be placed within the compression mold press, used to fabricate each hard armor plate, along with the various plies of Dyneema® HB25, or other similar ballistic material, during the lay-up phase, and integrated into the matrix of the hard armor plate. This process coats the exterior with a roughly 0.05″ thick outer layer of polymer, significantly enhancing the overall durability of each hard armor plate. Other types of materials and processes can be used to formulate variations of this method based on the requirements of each particular system as would be known to one of skill in the art.

Each soft armor panel consists of an exterior fabric comprised of a woven mesh of ballistic fibers that are covered with a camouflage pattern specific to each particular application. Ballistic fabrics are formed using any one of a number of ballistic fibers either alone or in combination with one another, including aramid and ultra high molecular weight polyethylene (UHMWPE) fibers. Beneath the exterior layer of material will be a layer of ballistic fiber mats roughly 0.25″ to 0.5″ thick. These fiber mats will be formed using any one of a number of readily available ballistic fabrics such as Twaron®, Kevlar®, or Dyneema®, alone, or in combination with each other, in order to provide NH Level IIIA protection or better, to all lateral portions of the wearer's torso.

EXAMPLES

According to the present invention, the preferred ballistic materials for use with the body armor protection system of the present invention is a UHMWPE, .g. Spectra Shield® or Dyneema®, for the reasons listed below. Of course, other materials may be used as would be known to one of skill in the art.

Highest Tenacity

UHMWPE polyethylene fibers have the highest strength-to-weight ratio of any fiber on the market. Not only is UHWMPE 10 times stronger than steel on a per unit weight basis, it is also about 40 percent stronger than aramid fibers, four times stronger than nylons and polyesters, and generally twice as strong as most carbon fibers.

Highest Modulus

UHMWPE leads a field of high-modulus fibers that include aramid, boron, “E” and “S” glass, HT graphite, and liquid crystal polymer. All of these provide high-strength, light-weight contrasts to metals, and all have high stiffness. UHMWPE can have up to 40 times the tensile modulus of nylon and twice that of aramid fibers.

Highest Energy-To-Break

In a measure of toughness called energy-to-break, the energy required to rupture a yarn in a tensile test, UHMWPE ranks the highest of all high-performance fibers. Toughness is determined by the combination of high elongation and high strength which translates into excellent energy absorption capabilities, which are important qualities for ballistics and impact resistance applications.

Strain-Rate Dependence Response

The faster you pull on the Spectra Shield® material, the stronger it becomes. This, together with a feature known as strain-wave velocity, makes Spectra Shield® a premier performer in ballistics. Aramids, by contrast, ranks lower in these characteristic.

Rapid Energy Dissipation

In a ballistic application, UHMWPE fibers redirect the energy of the incoming bullet, sending it along the path of the fiber.

Abrasion Resistance

UHMWPE ranks first in abrasion resistance among all high performance fibers. UHMWPE is impervious to most solvents and its low coefficient of friction (“slickness”) minimizes the effects of abrasion. UHMWPE has demonstrated up to 20 times the abrasion resistance of aramid fibers.

Cut Resistance

UHWMPE's molecular structure and low coefficient of friction combine to give it good, cut-resistance performance, whether due to repetitive abrasion or impact cuts.

Vibration Damping

This, in effect, is Spectra Shield® internal response to impact where energy is absorbed. In certain composite application, such as sporting goods, the inclusion of Spectra Shield® helps dampen impact induced vibration. The impact, normally dissipated via vibration only, is instead absorbed by the material.

Resistance to Internal Fiber Friction

Filament-to-filament wear, for example within a rope, creates internal abrasion. UHMWPE fibers can slide over one another, with minimal destruction from the internal filament abrasion.

Resistance to Flex Fatigue

Repeated flexing fatigues a fiber or wire, leading to loss of strength and breakage. But flex after flex, bend after bend, Spectra Shield® resists this deformation and retains its strength better than any other high modules fiber. In cordage, for example, Spectra Shield®'s performance in over-sheave (or pulley) cycling is a major benefit. With Spectra Shield®, there is less need for the kind of equipment modifications normally required with the use of high-modulus lines.

Water Behavior

UHMWPE neither absorbs water, nor deteriorates in water. UHMWPE maintains its ballistic properties when wet. In addition, unlike most other high performance fibers including aramids and carbon fiber, UHMWPE is naturally buoyant, i.e., it will float on water.

Low Dielectric Constant

In the megahertz and gigahertz frequency ranges, UHMWPE has a very high level of transmittance, i.e., any electromagnetic signals in this energy range will not be interfered with.

Table 2 below lists example characteristics of UHMWPE ballistic material, Spectra Shield Plus PCR⁶. ⁶www.honeywell.com

TABLE 2 Roll Weight (1) 87 lb. 39.5 kg Width 54-0.5 in 1.37-0.013 m Thickness 0.005-0.002 in 0.13-0.05 mm Areal Density 2.8-0.45 oz/yd² 95-15 g/m²

The soft armor border as represented both in images and CAD files shows an inaccurate thickness of 0.0625 rather than 0.375″ as it should be.

In the attached drawings and CAD files there are no images or data to represent the shin, shoulder or gauntlet pad as they will appear when fully assembled.

Neither images nor CAD files have a representation of the complete assembly in terms of straps and buckles.

Having now described a few embodiments of the invention, it should be apparent to those skilled in the art that the foregoing is merely illustrative and not limiting, having been presented by way of example only. Numerous modifications and other embodiments are within the scope of the invention and any equivalent thereto. It can be appreciated that variations to the present invention would be readily apparent to those skilled in the art, and the present invention is intended to include those alternatives.

Further, since numerous modifications will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to as falling within the scope of the invention. 

1. A body armor protection system comprising articulating joints wherein the articulating joints comprise at least two (2) stepped segments of varying thickness, one on each stepped segment, with adjoining angles between 45-75 degrees. 2-11. (canceled)
 12. The body armor protection system of claim 1, further comprising a harness support system, which comprises pressed foam.
 13. The body armor protection system of claim 1, further comprising a harness support system, wherein the harness support system is buoyant.
 14. The body armor protection system of claim 1, further comprising hard armor plate segments, wherein the plate segments comprise internal padding comprising channels, which allow for air circulation and moisture removal.
 15. The body armor protection system of claim 1, further comprising hard armor plate segments, wherein the plate segments comprise internal padding to protect a wearer from blunt force impact trauma, prevent plate deformation, and to support an adjustable strap system.
 16. The body armor protection system of claim 1, further comprising hard armor plate segments, wherein the plate segments further comprise external pressed foam padding to protect the exterior of each plate segment.
 17. The body armor protection system of claim 1, further comprising hard armor plate segments and a 2″ band of soft armor to add protection to peripheral areas not covered by the plate segments.
 18. A body armor comprising an articulating plate assembly with adjoining seam lines, wherein the articulating plate assembly comprises plate segments comprising at least a two step variation in the thickness of each segment along the adjoining seam line between each plate segment.
 19. The body armor of claim 18, wherein the articulating plate assembly comprises angular cuts between the plate segments.
 20. The body armor of claim 18, wherein the articulating plate assembly provides greater coverage without hindering mobility.
 21. A body armor comprising a lower leg protection system, wherein the lower leg protection system is configured to follow the contours of a wearer's knee to protect the knee cap and places the force of the wearer's body against the upper portion of a wearer's shin to alleviate any potential wear stress on the knee. 